Method and apparatus for producing rectangular contact holes utilizing side lobe formation

ABSTRACT

An array of small square contact holes, on the order of magnitude of the exposing light wavelength, are formed by selecting the partial coherence and numerical aperture of the exposing light source and the pitch of the array of windows on an attenuating phase shifting mask so that side lobes formed by the exposing light being diffracted as it passes through the array of window constructively interfere with one another in the vicinity of a desired contact hole on the material surface. This constructive interference of side lobe patterns, in combination with the pattern formed by the light passing undiffracted through the array of windows, forms an array of square exposed regions on the material surface. When the material is a photoresist, the exposed regions can be selectively dissolved in order to form square patterns that can be used to etch square holes in the underlying substrate or layer. In subsequent steps, selected ones of the array of square holes can be filled in with a conductive material to form vias and selected others of the square holes can be filled in with an insulating material so as to avoid the formation of unintended vias or conducting paths.

FIELD OF THE INVENTION

[0001] This invention relates generally to photolithography for semiconductor fabrication and more particularly to forming quadratic contact holes and similar features using constructive interference of side lobe formations.

BACKGROUND OF THE INVENTION

[0002] As semiconductor feature sizes continue to shrink into the sub-micron range, the effects of light diffraction during photolithographic processes become more pronounced. Deep ultraviolet (UV) exposure tools use light sources having a 248 nm wavelength. When such tools are used to form semiconductor devices having feature sizes of 200 to 300 nm, the effects of light diffraction become quite pronounced.

[0003] One area where diffraction effects are a particular problem is in the formation of small rectangular features, such as contact holes and vias. Square features on a photomask pattern become rounded due to diffraction when the substrate wafer is exposed. Rounded holes have a greater resistance than rectangular contact holes of similar size, resulting in greater contact resistance. In order to prevent the increased resistance, a larger diameter round contact hole would be required, resulting in lower packing density (i.e. a greater spacing requirement). In either event, the rounded contact hole is less desirable than a rectangular contact hole of similar size.

[0004] The use of attenuated phase shift masks is well-known to offset the problems associated with light diffraction in small feature size products. The prior art offers many solutions which are geared toward eliminating side lobe patterns resulting from diffraction effects. For instance, Tzu teaches the use of an opaque ring around the phase shifting features to reduce the effects of side lobe formation in U.S. Pat. No. 5,935,736. Choi et al. teach the formation of “dummy” open regions in the phase shift mask, which dummy regions allow light to pass through unimpeded and 180 degrees out of phase with diffracted light that would otherwise form side lobes below the dummy open region in U.S. Pat. No. 5,591,550. Garza, in U.S. Pat. No. 5,795,682, also teaches the use of guard rings to destructively interfere with, and hence eliminate, side lobe patterns. Sugawara teaches the use of alternating patters of phase shifting and non-phase shifting patterns to cause destructive interference of side lobe patterns in U.S. Pat. No. 5,487,963.

[0005] The shortcoming of the prior art is that the various techniques to reduce or eliminate side lobe formation do not address the need for forming good rectangular patterns in dense patterns of small features. The present invention overcomes the shortcoming of the prior art, as will become apparent from the following description of preferred embodiments of the invention.

SUMMARY OF THE INVENTION

[0006] In one aspect, the present invention provides a method of forming a quadratic hole on a surface comprising coating the surface with a photoresist layer and exposing the photoresist layer to a light source, the light source having passed through a photomask. The photomask comprises a first window corresponding to the desired quadratic feature, whereby light from the light source and passing through the first window exposes a first portion of the desired quadratic feature on the surface, and a plurality of adjacent windows, whereby light passing through the adjacent windows form diffraction patterns. The diffraction patterns constructively interfere to expose a second portion of the desired quadratic feature on the surface. Finally, the photoresist layer is selectively dissolved to remove exposed portions of the photoresist layer and the portions of the surface underlying the portions of the photoresist layer that were removed are etched to form quadratic holes.

[0007] In another aspect, the present invention provides for an integrated circuit. The circuit includes a substrate, a conductive layer overlying the substrate, and an insulating layer overlying the conductive layer. The integrated circuit further includes a rectangular contact hole passing through the insulating layer to the conductive layer, the rectangular contact hole having been formed by exposing a photoresist layer on the surface of the insulating layer through a photomask with a plurality of rectangular windows, the rectangular windows having a pitch such that, for a given partial coherence of the exposing light source, the side lobe features formed from the rectangular windows constructively interfere to expose a rectangular portion of the photoresist layer.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The above features of the present invention will be more clearly understood from consideration of the following descriptions in connection with accompanying drawings in which:

[0009]FIG. 1 illustrates a system for photolithographically forming patterned features on the surface of a substrate;

[0010]FIGS. 2a and 2 b illustrate a prior art attenuated phase shift photomask and the spectral intensity profile of light passing through a small feature on the photomask;

[0011]FIGS. 2c and 2 d illustrate the resulting exposure pattern including side lobe formation for a single small feature on a prior art attenuated phase shift photomask and for an array of small features on the prior art attenuated phase shift photomask;

[0012]FIGS. 3a and 3 b illustrate in plan view a preferred embodiment phase shift mask and resulting exposure pattern, respectively; and

[0013]FIGS. 4a through 4 g illustrate process steps for forming a square contact hole.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0014] The making and use of the various embodiments are discussed below in detail. However, it should be appreciated that the present invention provides many applicable inventive concepts which can be embodied in a wide variety of specific contexts. The specific embodiments discussed are merely illustrative of specific ways to make and use the invention, and do not limit the scope of the invention.

[0015]FIG. 1 illustrates in schematic form, a photolithographic processing stepper 10. The stepper comprises a light source 2 which is used to illuminate a photosensitive layer (a photoresist layer) 4 formed on a semiconductor wafer 6 or similar substrate. Patterns are formed on photoresist layer 4 by passing light from light source 2 through a photomask 8 upon which is formed the pattern desired to be transferred. The light also passes through focusing lens 9 prior to impinging upon layer 4.

[0016] Further details will now be provided for a preferred embodiment photomask 8. FIGS. 2a and 2 b illustrate a photomask 8 having a single pattern formed thereon, the pattern being a square opening. The pattern consists of a window region 10 surrounded by attenuating regions 12. Attenuating region 12 is formed by coating the photomask with an opaque material such as molybdenum silicide in the case of a 248 nm wavelength exposure light (for other wavelength exposure lights, different opaque material would be employed as is well known in the art). Preferably, this coating provides for about a 6% transmittance of light, although transmittance in the range of 4% to 20% will give acceptable results. Note from FIG. 2b that light passing through region 12 travels one half a wavelength further through the photomask than light passing through open window 10, resulting in a 180° phase shift between light passing through open window 10 and region 12. This phase shift will tend to lessen, but not eliminate, the intensity of the diffraction patterns 16 formed as light passes through open window 10, as shown in FIG. 2b. Curve 14 of FIG. 2b represents the intensity of light passing through photomask 8 and impinging upon photoresist layer 4. As shown, the light intensity is highest beneath open window 10, where the light from light source 2 passes through photomask 8 essentially unimpeded. Second order diffraction of the light results in peaks 16. Approximately 6% of the light from light source 2 passes through attenuating region 12, phase shifted by 180° as discussed above, which reduces but does not eliminate side lobe formation.

[0017]FIG. 2c illustrates the resulting pattern on the surface of photoresist layer 4. Note that two features are exposed on the layer. The first feature 18 corresponds to the region beneath open window 10. Note that the feature is essentially round due to corner rounding and other known diffraction phenomena. Side lobe 20 is also formed, corresponding to the region of light intensity 16 arising from the diffraction of light passing through open window 10.

[0018]FIG. 2d illustrates the resulting exposure pattern when a plurality of open windows 10 are formed on photomask 8. For each such open window 10, a feature 18 is exposed on photoresist layer 4. Again, features 18 show the corner rounding effects of diffraction resulting from the exposure process. Also shown are features 22, which correspond to those regions where side lobes 20 of adjacent open windows 10 constructively interfere with one another such that the combined intensity of the side lobes 20 in the regions 22 is sufficient to fully expose the photoresist layer 4. This results in unintended and undesirable features being formed on the semiconductor wafer 6, possibly resulting in short-circuits, unwanted current paths, and other performance degrading results.

[0019] In the preferred embodiments of the present invention, undesirable side lobe features 22 are eliminated and corner rounding of contact hole 18 is minimized by positioning open windows 10 relative to each other such that for an open window 10, the side lobes 20 associated the surrounding open windows 10 constructively interfere with each other in the region that corner rounding of contact 18 would otherwise occur. By positioning the side lobes to occur where it is desirable to expose the photoresist, undesirable features 22 are eliminated, and the shape of desired feature 18 is improved. The following paragraphs further illustrate the invention with preferred embodiment examples.

EXAMPLE 1

[0020]FIG. 3a illustrates a first exemplary photomask 8 used to create a pattern of small quadratic contact holes 18. Photomask 8 comprises attenuating region 12 and open windows 10. The resulting pattern on photoresist layer 4 is shown in FIG. 3b. The desired pattern to be exposed on photoresist layer 4 is an array of square shaped contact holes of size 225 nm by 225 nm. Photoresist layer 4 was comprised of a 5000 Angstrom thick layer of JSR M22G photoresist available from JSR, Corp., Tokyo, Japan, with a bottom antireflective coating of approximately 900 Angstroms thickness. The wafer was exposed using a Nikon DUV Scanner S203B with a numerical aperture of 0.68.

[0021] The photomask itself was formulated using attenuated phase shift photomask technology wherein attenuating region 12 provided for 6% transmittance. The pattern on the photomask was 4× the desired pattern on layer 4, with appropriate demagnification being accomplished via focusing lens 9. Deep UV light source 2 provides a partially coherent light beam with a 248 nm wavelength. Simulations dictated that side lobes 20 would constructively interfere in the desired corner regions of contact holes 18 when the 225 nm contact holes were spaced apart with a pitch of 350 nm (using a 248 nm wavelength light source). Hence open windows 10 were patterned on photomask 8 with a pitch of 350 nm.

[0022] In order to sufficiently expose photoresist layer 4 in the side lobe regions, the layer was overexposed at a rate of 78 mJ/cm². The partial coherence of light source 2 was selected at 0.44 sigma in order to generate sufficient side lobes to expose the corner regions of contact holes 18. A lower partial coherence would result in more side lobe formation (the intensity ratio between the main peak and the side lobe would become smaller). A greater partial coherence would hence result in lesser side lobe formation. Depending on the size of the contact mask feature, then, partial coherence can be readily adjusted for optimum side lobe formation. Typically, a partial coherence in the range of 0.3-0.65 will result in desirable side lobe formation for most desired feature sizes and pitches.

[0023] The resulting exposed photoresist layer 4 is illustrated in FIG. 3b. Note that a pattern of square contact holes is formed from the combination of rounded feature 18 forming the main portion of the contact hole and side lobe features 22 forming the corners portions. Although shown separately for illustration purposes, features 18 and 22 form a single feature (contact hole) in actual practice. Note that a novel and improved result is obtained by using the side lobe features to advantageous effect, rather than trying to minimize or eliminate those features as is taught in the prior art.

[0024] In the following examples, only select ones of the resulting contact holes 18 are required for further processing of an integrated circuit. The other contact holes 18 are necessary only to ensure that the selected contact holes have the desired square shape. Further processing is therefore preferred in order to eliminate unnecessary contact holes.

EXAMPLE 2

[0025] In this example, photoresist layer 4 has been exposed using the methods of any of the preceding examples, resulting in the pattern illustrated in FIG. 3b. Only the center-most contact hole 18, however, is needed for the circuit, the surrounding contact holes having been formed solely to ensure that the centermost contact hole has an acceptable square shape and to prevent undesirable side lobe features for forming around the desired contact hole.

[0026] In order to block out (remove) the unnecessary contact holes, a second exposure involving a second photoresist layer and a blocking photomask is employed. This blocking photomask will have an open window 10 only corresponding to the desired (center-most) contact hole, and the remaining contact holes will be placed under an attenuating region 12 of the blocking photomask. In this way, only the desired contact hole will be exposed during the second exposure step. In order to prevent the first photoresist layer 4 from being dissolved along with the exposed portions of the second photoresist layer, the first photoresist layer can be crosslinked prior to the second photolithographic step through radiation exposure, chemical cross-linking, e-beam exposure, or other well known cross-linking methods.

EXAMPLE 3

[0027] In this example, photoresist layer 4 has been exposed using the methods of the preceding examples, resulting in the pattern illustrated in FIG. 3b. FIGS. 4a through 4 g illustrate the process steps to eliminate the unnecessary contact holes, FIG. 4a provides a cross section view of semiconductor wafer 6, including conducting region 24 formed atop the wafer and insulating layer 26 formed atop the conducting region. Photoresist layer 4 has been photolithographically processed as described above, resulting in the patterned layer 4 illustrated in FIG. 4a. As will be apparent to one skilled in the art, desired contact hole 10′ is intended to provide a conductive pathway through insulating layer 26 by which electrical contact with buried conductive region 24 can be made.

[0028] In FIG. 4b, insulating layer 26, which is preferably a silicon dioxide or polysilicon layer is etched using known etching techniques. Three contact holes are etched into the layer because of the pattern of photoresist layer 4. In FIG. 4c, photoresist layer 4 is removed. In FIG. 4d a second photoresist layer 28 is applied and a blocking pattern is formed in layer 28. This blocking pattern is formed over desired contact hole 10′ only. Once second photoresist layer 28 has been exposed with the blocking pattern, the unexposed portions of the layer 28 is removed as shown in FIG. 4e. Next, unnecessary contact holes 10 are filled with an insulator material 30, such as plasma deposited polymer, spin coated polymer, or the like, as shown in FIG. 4f. In this way, the unnecessary contact holes are removed. Finally, as shown in FIG. 4g, the remaining photoresist layer 28 is removed, leaving a single contact hole 10 in the desired location.

[0029] As will be apparent from the above described examples, the present invention can be embodied in numerous embodiments. Square contact holes can be obtained for a variety of photolithographic processes, provided that the pitch and size of the open windows are adjusted to cause side lobe formation in the region of the contact hole corners, and that the illumination conditions (particularly partial coherence) is adjusted such that the photoresist layer is sufficiently exposed. Other light sources, such as commonly used 193 nm and 365 nm wavelength light sources can be employed with the teachings of the present invention, provided the partial coherence, numerical aperture, and focus are properly adjusted, as taught herein, for the size and pitch of the desired rectangular features.

[0030] While this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. It should be understood that the present invention also relates to machine readable media on which are stored reticle designs meeting the requirements of this invention, or program instructions for performing methods of this invention. Various modifications and combinations of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description. It is therefore intended that the appended claims encompass any such modifications or embodiments. 

What is claimed is:
 1. A method of forming a quadratic hole on a surface comprising: coating the surface with a photoresist layer; exposing the photoresist layer to an light source, the light source having passed through a photomask, wherein the photomask comprises a first window corresponding to the desired quadratic feature, whereby light from the light source and passing through the first window exposes a first portion of the desired quadratic feature on the surface; and at plurality of adjacent windows, whereby light passing through the adjacent windows form diffraction patterns, which diffraction patterns constructively interfere to expose a second portion of the desired quadratic feature on the surface; selectively dissolving the photoresist layer to remove exposed portions of the photoresist layer; and etching the surface underlying the portions of the photoresist layer that were removed to form quadratic holes.
 2. The method of claim 1 further comprising applying a second photoresist layer atop the etched surface; exposing all the second photoresist except for a portion overlying a selected quadratic hole; selectively dissolving the second photoresist layer to remove exposed portions of the second photoresist layer; depositing a material on the surface to fill uncovered quadratic holes; and removing the portion of the second photoresist overlying the selected quadratic hole.
 3. The method of claim 1 wherein combination of undiffracted light passing through the first window and the diffracted light passing through the plurality of adjacent windows exposes a quadratic feature on a top surface of the photoresist layer.
 4. The method of claim 1 wherein the surface is an insulating layer formed atop a semiconductor wafer.
 5. The method of claim 1 wherein the pitch and size of the first window and plurality of adjacent windows is selected to give constructively interfering side lobes in the region of the desired quadratic hole on the surface as a function of the partial coherence of the light emitted from the light source.
 6. The method of claim 1 wherein the light source emits light at a wavelength of 248 nm.
 7. The method of claim 4 wherein the quadratic hole forms a contact hole for making electrical connection to a conductive region underlying the insulating layer.
 8. The method of claim 5 wherein the size of the first window and the adjacent windows is about 200-250 nm, and the pitch between adjacent windows is about 320-380 nm and the light source has a partial coherence of about 0.3-0.6 sigma.
 9. The method of claim 1 wherein the photomask is an attenuating phase shift mask.
 10. The method of claim 8 wherein the light source has a numerical aperture of about 0.5-0.8.
 11. An integrated circuit comprising: a substrate; a conductive layer overlying the substrate; an insulating layer overlying the conductive layer; a rectangular contact hole passing through the insulating layer to the conductive layer, the rectangular contact hole having been formed by exposing a photoresist layer on the surface of the insulating layer through a photomask with a plurality of rectangular windows, the rectangular windows having a pitch such that, for a given partial coherence of the exposing light source, the side lobe features formed from the rectangular windows constructively interfere to expose a rectangular portion of the photoresist layer.
 12. The integrated circuit of claim 11 further comprising a conductive material formed within the rectangular contact hole.
 13. The integrated circuit of claim 12 further comprising a second conductive layer overlying the insulating layer and being in electrical contact with the first conductive layer via the conductive material formed within the rectangular contact hole.
 14. The integrated circuit of claim 12 wherein the pitch between adjacent rectangular windows is about 320-360 nm and the photoresist layer is exposed with light having a partial coherence of about 0.44 sigma.
 15. A method of forming a square contact hole in an insulating layer comprising: providing an photoresist layer atop the insulating layer; exposing the photoresist layer with a light source having a partial coherence of about 0.3-0.6 through a photomask having a plurality of square light transmissive windows, each window being about 200-250 nm on a side, whereby light passing through each window combines with light diffracted by each window on the photoresist layer to expose a square portion thereof; selectively dissolving the exposed portions of the photoresist layer; and etching the insulating layer beneath the exposed portions of the photoresist layer.
 16. The method of claim 15 wherein the photoresist layer is exposed with a light having a wavelength of 248 nm.
 17. The method of claim 15 wherein the photoresist layer is exposed with a light having a wavelength of 193 nm.
 18. The method of claim 15 wherein the photoresist layer is exposed with a light having a wavelength of 365 nm.
 19. The method of claim 15 wherein a plurality of square contact holes are formed simultaneously.
 20. The method of claim 19 wherein selected contact holes are subsequently filled with a conductive material and selected other contact holes are subsequently filled with an insulating material. 